Heat-vulcanizable silicone compositions from premix

ABSTRACT

An untreated filler and a high viscosity silicone polymer premix is charged into a compounding apparatus. Treating agent and additional silicone polymer are added to the premix and the premix, treating agent and additional silicone polymer are compounded to produce a heat vulcanizable filled silicone composition.

BACKGROUND OF THE INVENTION

The invention relates to a process for preparing heat-vulcanizable silicone compositions. Particularly, the invention relates to a process for preparing heat-vulcanizable silicone compositions from an untreated filler and silicone polymer premix.

A heat-vulcanizable silicone composition comprises a high viscosity silicone polymer, an inorganic reinforcing filler and various additives that aid processing or impart desired final properties to the composition. A vulcanizing agent can be added and the composition heat-cured to fabricate silicone rubber moldings such as gaskets, medical tubing and computer keypads.

The heat-vulcanizable silicone composition can be prepared from a concentrate called a premix. A premix is an extrudable composition formed of a blend of a polymer and a finely divided filler, prepared by combining the materials under high shear force conditions in the presence of a liquid processing aid. The liquid processing aid treats filler silanol groups. Residual silanol groups on the surface of the filler can govern strength of hydrogen bonds between the silica and hydroxyl or oxygen groups in the silicone polymer chain. High concentrations of residual silanols in a filler cause “structuring” or “crepe hardening” of the final product in storage. This effect leads to difficulties in the processing of the material after it has been stored for extended periods. Typically, a treating agent is added to reduce silanol functional groups to a required concentration.

Large interfacial forces develop between silicone polymer and free, unreacted silanol groups present in filler. The treating agent must diffuse through a bulk of the high molecular weight silicone polymer and penetrate a rigid silicone polymer/filler interface to reach reactive silanol groups. Hence heretofore, the treating agent has been added either directly to the silica before the premix forming step or during the premix forming step under conditions of high shear mixing.

A treated premix is a damp composition that is more difficult to store or to transport than a dry mix. Hence, treated premix is prepared and immediately charged into a subsequent extrusion step. For example, Kasahara et al., U.S. Pat. No. 5,198,171, discloses preparing a premix of polydiorganosiloxane, inorganic filler and liquid treating agents in a high speed mechanical shearing mixer. The resulting premix is then compounded in a same-direction double screw extruder.

The difficulties of storing and transporting a damp treated premix place limitations on premix use and marketability. There is a need for a filler and silicone polymer premix with extended use properties.

SUMMARY OF THE INVENTION

The invention provides a process that utilizes an untreated filler that has extended use properties. In the process, an untreated filler and a high viscosity silicone polymer premix is charged into a compounding apparatus. Treating agent and additional silicone polymer are added to the premix and the premix, treating agent and additional silicone polymer are compounded to produce a heat vulcanizable filled silicone composition.

In another embodiment, a premix is formed from filler and high viscosity silicone polymer in the absence of a treating agent. The untreated filler and high viscosity silicone polymer premix is charged into a compounding apparatus where treating agent and silicone polymer are added. The premix, treating agent and additional silicone polymer are compounded in the apparatus to produce a heat vulcanizable filled silicone composition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a process for preparing a untreated filler and silicone polymer premix and preparing a heat-vulcanizable filled silicone composition from the premix.

DETAILED DESCRIPTION OF THE INVENTION

According to the invention, high viscosity heat-vulcanizable silicone compositions are prepared directly from untreated premix. Untreated premix is a compounded mixture of a filler with silanol surface groups that have not been reacted with a treating agent and a high viscosity silicone polymer. Surprisingly, silanol groups of the silica of the premix can be adequately treated with treating agent during a subsequent compounding step with polymer gum in a high speed mixer or extruder.

The filler that can be used in the invention is any inorganic filler with silanol surface groups that can be used in blends with silicone polymers. Examples of inorganic fillers include a reinforcing silica such as fumed silica or precipitated silica. A single filler or a combination of fillers can be used to reinforce the silicone polymer.

The amount of filler in the premix can be from about 20 to about 150 parts by weight, desirably from about 30 to about 100 parts by weight and preferably from about 40 to about 70 parts by weight, per 100 parts by weight of the high viscosity silicone polymer. During the compounding step, addition of further silicone polymer reduces the proportion of filler in the final silicone composition to about 10 to about 100 parts by weight, desirably from about 15 to about 90 parts by weight and preferably from about 25 to about 70 parts by weight, per 100 parts by weight of the total high viscosity silicone polymer.

The high viscosity silicone polymer used in the compositions of the present invention is typically referred to as “gum” or “gum silicone.” The polymer has a viscosity greater than 1,500,000 cps at 25° C. The viscosity can be greater than 4,000,000 cps and preferably is greater than 8,000,000 at 25° C.

The polymer can be represented by recurring units of Formula I:

wherein, R¹ independently at each occurrence represents C₁₋₄ alkyl, or C₂₋₄ alkylene; R² independently at each occurrence represents C₁₋₄ alkyl, C₁-C₄ haloalkyl or C₂₋₄ alkylene; R³ independently at each occurrence represents H, C₁₋₁₀ alkyl, C₂₋₄ alkylene, C₄₋₆ cycloalkyl, OH or C₁-C₄ haloalkyl; and n represents an integer from 1,000 to 20,000.

A further preferred composition comprises a silicone polymer wherein, R¹ independently at each occurrence represents, CH₃ or CH═CH₂; R² independently at each occurrence represents, CH₃, CH═CH₂ or CH₂CH₂CF₃; R³ independently at each occurrence represents CH₃, CH═CH₂, OH or CH₂CH₂CF₃; and n represents an integer from about 4,000 to about 10,000.

Another embodiment provides a composition wherein the vinyl content of the silicone polymer ranges from about 0.05% to about 0.5% by weight of the silicone polymer.

The treating agent is a silanol or methoxy stopped silicone fluid that reacts with the filler surface hydroxyl or silanol groups to prevent a condensation reaction among filler particles or between filler and gum molecules that otherwise leads to stiffening and loss of elastomeric properties. The treating agent reduces filler silanol groups and reduces the time required for aging of the silicone, to prevent crepe hardening and/or to regulate plasticity. The treating agent can be an organosilane, a low-viscosity polysiloxane or a silicone resin, which has a silanol group and/or an alkoxy group having 1 to 6 carbon atoms. Examples include diphenylsilanediol, dimethylsilanediol, methyltriethoxysilane and phenyltrimethoxysilane. The low-viscosity polysiloxane may contain one or more kinds of organic groups selected from a methyl group, a phenyl group, a vinyl group and a 3,3,3-trifluoropropyl group. Preferred silanol-reactant treating agents include silanol-stopped polydimethylsiloxane, octamethylcyclotetrasiloxane (D4) and hexamethyldisilazane (HMDZ). The viscosity of the polysiloxane measured at 25° C. is in the range of from about 1 to about 300 cP, preferably from about 5 to about 100 cP.

The treating agent can be added in the compounding step in a weight proportion of about 0.1 to about 100 parts fluid to 100 parts of filler, desirably about 0.5 to about 75 parts fluid to 100 parts of filler and preferably about 1.0 to about 50 parts fluid to 100 parts of filler. The treating agent can react to reduce available groups of the filler to a concentration of between about 8 to about 2 hydroxyl groups/(nanometer)² of filler, preferably between about 7 to about 3 hydroxyl groups/(nanometer)² of filler. In an embodiment, the treating agent can be a combination of HMDZ and water. This combination can comprise a weight ratio of HMDZ/water of between about 1/0.1 to about 1/10 or between about 1/0.5 and about 1/5 or between about 1/1 and about 1/3.

The heat-vulcanizable silicone composition can also include other additives such as heat-resistance improvers such as oxides, hydroxides and fatty acid salts of metals, vulcanization reverse inhibitors, flame retardants such as platinum compounds, discoloration preventive agents, plasticizers such as silicone oil, internal release agents such as metal soaps, pigments and dyes.

Drawing FIG. 1 is a schematic representation of a process for preparing an untreated filler and silicone polymer premix and preparing a heat-vulcanizable filled silicone composition from the premix. In FIG. 1, untreated filler and silicone polymer are fed, 12 and 14, into first mixer 16, where an untreated premix is formed. The untreated premix is discharged directly 18 to feeder 20 or is sent 22 to a storage receptacle or area 24 for later charge 26 to the feeder 20 or to another process 28 conducted at another location. Feeder 20 dispenses 30 untreated premix and feeder 32 dispenses 34 treating agent to second mixing apparatus 36, where the premix is treated and compounded with additional silicone polymer 38 to produce a filled heat-vulcanizable silicone polymer composition 40.

First mixer 16 can be any suitable mixer. However, in one embodiment of the invention, mixer 16 is a continuous annular layer mixer comprising a cylindrical mixing trough wherein material to be mixed is propelled along a helical path along the axis of the trough in the form of a ring contiguous with the cylindrical mixer wall. A typical continuous annular layer mixer is disclosed in Erich et al., U.S. Pat. No. 5,018,673 describing a mixer comprising an essentially horizontally arranged cylindrical housing, which is provided at a first end with a material supply pipe for a continuous supply of material and, at a second end, with a material discharge pipe for a continuous removal of material. The cylindrical housing encloses a mixing apparatus, which is arranged coaxially in the housing. The mixing apparatus is driveable at high speeds. The apparatus comprises mixing tools, which project essentially radially from the apparatus into the vicinity of the housing inner wall.

Second mixer apparatus 36 is illustrated as a mixer. However, apparatus 36 can be any suitable compounding apparatus. A co-rotating, intermeshing extruder, a counter-rotating, intermeshing or non-intermeshing extruder, a single-screw reciprocating or non-reciprocating extruder and a co-rotating, self-wiping extruder are examples of apparatus 36.

These and other features will become apparent from the following detailed discussion, which by way of example without limitation describes preferred embodiments of the present invention.

EXAMPLES

A premix was prepared in a 10L Henschel mixer by charging 66.6 parts of a silicone gum (penetration of 800, 0.2 m %), 33.3 parts of a silicone gum (penetration of 800, 0.5 m %) and 53.5 parts of a fumed silica with a 200 square meter/gram surface area (A-200 Degussa filler). The mixer was rotated for 20 minutes at 3500 RPM. The resulting premix had a talcum powder like appearance with a tap density between 0.42 to 0.46. This premix was used in formulations shown in Table 1.

Formulations 1001, 1002, 1004 and 1005 of Table 1 were prepared by adding premix to a Henschel mixer along with a silanol fluid plasticizer, a methoxy stopped fluid plasticizer and a vinyl triethoxy silane crosslinker. HMDZ was added in the preparation of formulations 1002 and 1005 and the HMDZ and premix were mixed for 5 minutes in the Henschel mixer prior to adding other additives. Premix and additives were mixed till massed. Each batch was then heated to 70° C. to 80° C. and held at this temperature range for ½ hour with a nitrogen purge. The batch was then heated to 150° C. and cooked for 30 minutes.

Formulations 1003 and 1006 were made by mixing a silicone gum (penetration of 800, 0.2 m %) and a different gum (penetration of 800, 0.5 m %) in the mixer for 10 minutes followed by addition of HMDZ and further mixing for 5 minutes. Twenty (20) percent of the filler was added and mixing continued for 15 to 20 minutes. A vinyl triethoxy silane crosslinker was added and mixing was continued for 5 minutes. Then 20 percent of filler was added and mixing continued for 15 to 20 minutes. Then a methoxy stopped fluid plasticizer was added and mixing continued for 5 minutes. Twenty (20) percent more of the filler was added and mixing continued for 15 to 20 minutes followed by heating of the batch to 120° C. with a nitrogen purge. Fifteen (15) percent more of the filler was added and mixing continued for 15 to 20 minutes. One-half of an amount of silanol fluid plasticizer was added and mixing continued for 25 minutes. Then a final 15 percent of filler was added and mixed for 10 to 15 minutes followed by addition of the remaining plasticizer, and the batch was mixed for 10 minutes followed by heating to 150° C. and cooking for 30 minutes.

The formulations were catalyzed using 1.5 parts 2,4-dichlorobenzoyl peroxide, for every 100 gm of formulation. The catalyzed formulation was press cured for 12 minutes at 260° C. on a cold mold. The press cured formulations were further cured at 200° C. for 4 hours in an oven. Physical properties were evaluated after equilibrating the post-cured sheets in a controlled humidity environment for 3 hours.

Formulations are reported in the following Table 1.

TABLE 1 Formulation(gms)/ Sample 1001 10002 1003 1004 1005 1006 Premix 921 9921 1427 1415 silanol fluid treating 24.6 244.6 24.6 38.1 37.8 37.8 agent methoxy fluid treating 15.6 155.6 15.6 24.2 23.9 23.9 agent vinyl triethoxy silane 4.9 44.9 4.9 7.5 7.5 7.5 crosslinker HMDZ 66.8 6.8 10.4 10.4 DI water 5.2 5.2 silicone polymer 399.6 614 (800, 0.2 m %) silicone polymer 200.4 307.9 (800, 0.5 m %) fumed silica 321 493.2

Properties for the Table 1 formulations are reported in Table 2. In Table 2, Williams Plasticity was measured on 100 gms samples. Nip thickness was between ⅜±⅛″. Fifteen (15) end to end passes were made and the sample was rested for 10 minutes. All listed times were taken from an initial three minute pass with a Williams plasticity meter.

Shore A hardness was measured on three cut-out dumbbells, stacked no less than 0.21″ high. Three measurements were taken and the average is reported in the Table 2.

Tensile, elongation and modulus were measured on samples cut in accordance with ASTM D412-87. Dumbbells were pulled until failure. Averages are reported in Table 2.

Tear resistance was measured on samples cut as per ASTM D624-86. A 0.0020±0.002 inch nick was made in each sample. The samples were pulled till tear. Averages are reported in Table 2.

Specific gravity was measured using a ratio of sample weight in air to sample weight in water. Compression set was determined by measuring thickness of samples on heating in an oven at 350° F. for 22 hours. Volatiles were determined (C-9%) by loss in weight of samples as measured at 135°±5° C. for 45 minutes at a vacuum of 20 mm Hg±5 mm Hg.

TABLE 2 Property/Sample 1001 1002 1003 1004 1005 1006 Specific Gravity 1.194 1.18 1.191 1.169 1.191 1.19 Shore A Hardness (Durometer) 70.8 63.9 73.2 70.4 63.5 70.3 Tensile Strength (psi) 1154 1364 1249 1389.6 1519.2 1405.2 Elongation (%) 231 292 241 266.4 308.8 312.4 100% Modulus 425 326 491 428.8 322.8 395.5 Tear B (ppi) 78 80 .80 81.2 85.6 94.5 C/S 22 hr, 350 F (%) 61.7 52.2 57.8 49 43.6 16.8 C-9 (%) 27, 23 35, 33 34, 40 Williams Plasticity 10 min 251 276 406 332 306 372 24 hr 341 340 593 478 358 414  2 day 505 385 635 518 389 444  3 day 534 387 701 577 405 451  1 week 727 457 777 674 456 482  2 week 871 495 827 790 489 525  3 week 875 510 853 860 503 552  4 week 982 542 972 907 524 570  2 month 1042 605 743 TRAN 77.4 78.2 80 Y1 14.5 12.8 13.3 HAZE 58.4 57.8 37.8 L 88.1 88.6 89.6 A 0 0.4 −0.4 B 7.2 6.2 6.8 Shrink L (%) 3.5 3.1 3.6 W (%) 0.9 1.1 0.8

Suitable heat-vulcanizable silicone polymer compositions meet the following physical property standards: Williams Plasticity of greater than 100, Shore A hardness of greater than 20, tensile strength of greater than 750 psi, elongation at break of at least 100%, Tear B of at least 10 ppi and Specific Gravity of at least 1.05. Formulations 1002 and 1005 show lower structuring and plasticity over time. The lower durometer and excellent plasticity show that 1002 and 1005 experienced adequate filler treatment. Formulation 1005 shows the importance of adding distilled water for varying treatment levels.

While preferred embodiments of the invention have been described, the present invention is capable of variation and modification and therefore should not be limited to the precise details of the Examples. The invention includes changes and alterations that fall within the purview of the following claims. 

What is claimed is:
 1. A process of preparing a heat-vulcanizable filled silicone composition, comprising: charging a premix comprising an untreated filler said filler containing surface silanol groups and high viscosity silicone polymer into a compounding apparatus; adding HMDZ, a silanol stopped silicone or a methoxy stopped silicone fluid treating agent and additional silicone polymer to said premix; and compounding said premix, treating agent and additional silicone polymer to produce a heat vulcanizable filled silicone composition.
 2. The process of claim 1, wherein said treating agent is HMDZ.
 3. The process of claim 1, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/0.1 to about 1/10.
 4. The process of claim 1, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/0.5 to about 1/5.
 5. The process of claim 1, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/1 to about 1/3.
 6. The process of claim 1, wherein each of said silicone polymers has a viscosity greater than 1,500,000 cps at 25° C.
 7. The process of claim 1, wherein each of said silicone polymers has a viscosity greater than 4,000,000 cps at 25° C.
 8. The process of claim 1, wherein each of said silicone polymers has a viscosity greater than 8,000,000 cps at 25° C.
 9. The process of claim 1, wherein said premix comprises about 20 to about 150 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 10. The process of claim 1, wherein said premix comprises about 30 to about 100 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 11. The process of claim 1, wherein said premix comprises about 40 to about 70 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 12. A process of preparing heat-vulcanizable filled silicone compositions, comprising: forming a premix from an untreated filler said filler containing surface silanol groups and high viscosity silicone polymer in the absence of a treating agent; charging said untreated filler and high viscosity silicone polymer premix into a compounding apparatus; adding HMDZ, a silanol stopped silicone or a methoxy stopped silicone fluid treating agent and silicone polymer to said premix; and compounding premix, treating agent and silicone polymer to produce a heat vulcanizable filled silicone composition.
 13. The process of claim 12, comprising storing said premix for at least 24 hours prior to charging into said compounding apparatus.
 14. The process of claim 12, wherein said treating agent is HMDZ.
 15. The process of claim 12, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/0.1 to about 1/10.
 16. The process of claim 12, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/0.5 to about 1/5.
 17. The process of claim 12, wherein said treating agent is a combination of HMDZ and water in a weight ratio of HMDZ/water of between about 1/1 to about 1/3.
 18. The process of claim 12, wherein said premix comprises about 20 to about 150 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 19. The process of claim 12, wherein said premix comprises about 30 to about 100 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 20. The process of claim 12, wherein said premix comprises about 40 to about 70 parts by weight filler per 100 parts by weight of high viscosity silicone polymer.
 21. The process of claim 12, wherein each of said silicone polymers has a viscosity greater than 1,500,000 cps at 25° C.
 22. The process of claim 12, wherein each of said silicone polymers has a viscosity greater than 4,000,000 cps at 25° C.
 23. The process of claim 12, wherein each of said silicone polymers has a viscosity greater than 8,000,000 cps at 25° C. 